Simulated log siding

ABSTRACT

Simulated log siding is formed of an engineered cementitious composite. Single or dual flanges on each log piece is used to apply siding units to a surface. Some siding members are molded into a three dimensional configuration to appear as a structural wood log. Individual end pieces and molded tail clusters when used with the siding provide the appearance of the characteristic stacked or staggered corners of a log structure.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/096,252, filed Dec. 4, 2013, which is a continuation of U.S. patentapplication Ser. No. 13/667,132, filed Nov. 2, 2012, now abandoned,which is a continuation of U.S. patent application Ser. No. 12/077,388,filed Mar. 17, 2008, now U.S. Pat. No. 8,302,355 B2, issued Nov. 6,2012, which claims the benefits of U.S. Provisional Application No.60/918,619, filed Mar. 15, 2007, the disclosures of which are herebyincorporated by reference in their entirety including all figures,tables and drawings.

BACKGROUND OF THE INVENTION

Log buildings are in high demand due to their aesthetic appeal. Thesestructures however can be expensive not only to construct but also tomaintain and insure. Log structures are vulnerable to damage fromexposure to water, temperature changes, insect infestation and firedamage. Log siding has always been a less expensive alternative forthose seeking the log home look, but log sided structures aresusceptible to many of the same effects as log structures. Cement siding(U.S. Pat. Nos. 4,288,954 and 7,028,436 B2) and cement logs (U.S. Pat.No. 6,851,233 B2) have been produced to address some of these concerns.These alternatives however are not necessarily appropriate for ado-it-yourselfer (DIY) and often cannot be mass produced. O'Donnell, forexample, describes a siding where several layers of cement plaster mustbe hand-applied to log shaped metal lath on the structure to be sided.The O'Donnell process requires various secondary materials and skilled,on-site, labor.

There remains a need for a simulated log siding that is inexpensive yetconveys a genuine wood log appeal. Ideally, the log-like siding would beresistant to environmental effects, DIY compatible and be fireresistant.

All patents, patent applications, provisional patent applications andpublications referred to or cited herein, are incorporated by referencein their entirety to the extent they are not inconsistent with theteachings of the specification.

SUMMARY OF THE INVENTION

The invention involves a siding material cast or formed of an engineeredcementitious composite (ECC) that simulates the look of a structuralwood log. Open molds, closed molds for injection molding, or anextrusion process are used to create various face surfaces and variousend piece surfaces giving the piece the appearance of a structural woodlog. Siding pieces are hollow or incorporate a core material to providea solid piece. Siding pieces, “logs,” are applied to a surface byattaching flanges associated with each piece to a structural surface.

The invention also involves cast filler blocks and tail clusters of anECC to provide a structure covered by the subject siding with a logstructure's characteristic woven, stacked or staggered corners.Individual end caps with a log pattern end cut are applied to sidingedges to make the log ends appear to be complete log butts.Alternatively, a cast tail cluster of a series of log ends can beattached to the corner of a sided structure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a preferred embodiment of an insidecorner of a structure sided with the simulated log siding of the subjectinvention.

FIG. 2 is a top plan view of the corner shown in FIG. 1.

FIG. 3 is a perspective view of a front side of a preferred embodimentof a siding piece of the subject invention.

FIG. 4A is a cross-sectional view of a preferred embodiment of a sidingpiece of the subject invention having a simulated peeled log appearanceand a foam core.

FIG. 4B is a cross-sectional view of a preferred embodiment of a sidingpiece of the subject invention having a simulated peeled log appearance.

FIG. 5A is a cross-sectional view of a preferred embodiment of a sidingpiece of the subject invention having a simulated hand hewn logappearance and a foam core.

FIG. 5B is a cross-sectional view of a preferred embodiment of a sidingpiece of the subject invention having a simulated hand hewn logappearance.

FIG. 6A is a face side view of another preferred embodiment of thesimulated log siding of the subject invention with reinforcing ribs.

FIG. 6B is a back side view of another preferred embodiment of thesimulated log siding of the subject invention with reinforcing ribs.

FIG. 6C is a side elevational view of another preferred embodiment ofthe simulated log siding of the subject invention with reinforcing ribs.

FIG. 6D is an end view of another preferred embodiment of the simulatedlog siding of the subject invention with reinforcing ribs.

FIG. 7A is a face side view of another preferred embodiment of thesimulated log siding of the subject invention.

FIG. 7B is a back side view of another preferred embodiment of thesimulated log siding of the subject invention.

FIG. 7C is a side elevational view of another preferred embodiment ofthe simulated log siding of the subject invention.

FIG. 7D is an end view of another preferred embodiment of the simulatedlog siding of the subject invention.

FIGS. 8A-C are environmental views of a preferred manufacturing processof the log siding of the subject invention.

FIG. 9A is a cross-sectional view of a siding piece of the embodimentshown in FIG. 6.

FIG. 9B is a cross-sectional view of a siding piece of the embodimentshown in FIG. 6 on a structure in relation to other like siding pieces.

FIG. 10 is a perspective view of the embodiment shown in FIG. 6 on astructure exploded at the seam to show the vertical joint piece.

FIG. 11 is a top plan view of a staggered-style corner of a structuresided with the siding of the subject invention using filler blocks.

FIG. 12A is a perspective front left side view of a preferred embodimentof a filler block of the subject invention.

FIG. 12B is a perspective front right side view of a preferredembodiment of a filler block of the subject invention.

FIG. 12C is a perspective rear view of a preferred embodiment of afiller block of the subject invention.

FIG. 13 is an exploded side view of a staggered-style corner where thefiller block completes the half log siding.

FIG. 14 is a perspective view of an outside corner using filler blocksin a staggered-style corner joint.

FIG. 15 is a top plan view of an outside corner with a preferredembodiment of a tail cluster in place.

FIG. 16 is a perspective view of the corner shown in FIG. 15.

FIG. 17 is a top cross-sectional view of a corner sided with the sidingof the subject invention.

FIG. 18 is an exploded perspective view of the corner shown in FIG. 17.

FIG. 19A is a top plan cross-sectional vie of a preferred embodiment ofan exterior corner piece.

FIG. 19B is a top plan cross-sectional vie of a preferred embodiment ofan exterior corner piece attached to a structure sided with the sidingof the subject invention.

DETAILED DESCRIPTION OF THE INVENTION

The simulated wood log siding of the subject invention comprises logshaped pieces (FIG. 3). Each piece is about the length of a structuralwood log, for example, from about eight feet to about twelve feet.Engineered cementitious composite is cast or sprayed in a mold takenfrom a structural wood log. The molds 24 can be taken from any type oflog including peeled (FIG. 4), partially peeled, and hand hewn (FIG. 5)logs and the mold preferably includes details of the butt end portion ofthe log. In some embodiments, urethane foam is blown into the cast moldto form a solid log shape.

The siding pieces 10 of the subject invention are preferably the lengthof a structural log, about eight to twelve feet, to provide an authenticlog structure appearance. Pieces are cast or formed in flexible openmolds, flexible closed molds by injection molding, or by an extrusionprocess as a sheath or solid body. In a preferred embodiment, the piecesare cast of an engineered cementitious composite (ECC). One skilled inthe art is able to identify and formulate suitable ECCs to provide theflexural strength required for the length of each the siding pieces. Afoam, wire or solid core can also be incorporated into the siding pieceto provide flexural strength. One skilled in the art would likewise beable to identify and formulate suitable materials for casting sidingpieces that are shorter or for filler blocks and tail clusters.

Fastening flanges 12 can assist in fastening the subject siding to awall. Fastening flanges 12 along the long edges of each “log” 10 areembedded in the ECC material or are formed by the ECC material. In apreferred embodiment, the flange is a material embedded in the material.A hinge on the mold support can cover the flange material to prevent iffrom being fowled with ECC and foam. Flange material useful in thesubject invention can be anything strong enough to support the sidingpiece and secure it to the structure. Suitable flange material includes,but is not limited to, metal hardware cloth, metal lath, black UV polydeer fence netting and sunblocker POLYMAX black knitted shade material.Alternatively, the flange can include special brackets or tabs to attachthe siding to the structure. The chosen flange material dictates theattachment schedule to attach the siding to a wall.

In another preferred embodiment, one or duo the attachment flanges 12are formed while casting or forming the piece. The flange is molded ontothe “log” (see, for example, FIG. 9). In a preferred embodiment,reinforcing ribs 16 preferably span the width of the log for support.The ribs are most preferably 16 inches on center and provide a smallspace behind the siding piece to protect the wall from trapped moisture.Fastening pilots 18 are spaced along the flange through which a fastenercan be placed to secure the piece to the structure (FIG. 6). Preferably,flange edges 19 (FIG. 9B) are beveled. The bevel allows one siding pieceto engage the flanges of other siding pieces above and below it on thewall.

An advantage of the subject siding is that it can be mass produced. Onemeans by which the subject siding can be mass produced is shown in FIG.8 where a single male mold 20 can be used while multiple female molds 22pass on a conveyor (not shown). The female molds move to a curingstation after casting. The expected dwell time to cast a 12 foot longpiece is about 15 seconds.

Siding pieces are applied to the wall to simulate a log structure.Fasteners to secure the siding to the wall are chosen as appropriate forthe wall substrate. Gaps left between the secured “logs” can be filledwith chinking to complete the illusion of an authentic log cabin.

Siding pieces are installed over the structure's sheathing 24 and over avapor barrier 26. When a wall being covered is longer than the length ofthe siding piece, for example, greater than 12 feet, a vertical jointpiece 28 can be inserted at the butt joint (FIG. 10). Alternatively, thelog surface molds 20 are designed so that the log surface pattern nearthe end of each “log” coordinates and matches with the surface patternof an adjacent log mold so that when pieces are butted they appear to bea continuous piece.

The exterior corners of a structure sided with the simulated wood logsiding of the subject invention can be finished in a number of ways. Theexterior corners can be capped by a corner post. A square corner post(FIG. 19) is shown however a round corner post can also be used. Thecorner post 31 has a foam core 14 covered by ECC resembling a woodenpost 29. Interior corners likewise can be finished in a corner post 30(FIGS. 1 and 2). Alternatively, the ends of each siding piece can bemitered to join one another and form a corner both on interior andexterior corners.

A more traditional stacked or staggered look on external or exteriorcorners can be achieved on a structure sided with the simulated wood logsiding of the subject invention by using end filler blocks or cast tailclusters. Filler blocks 32 can be used to achieve a stacked look (FIGS.11-14). As noted previously, molds preferably include details of thebutt end portion of the log 33. The blocks complete these siding piecesthat extend past the corner of the structure to provide a look of acomplete, as opposed to a half, log end (FIG. 13). Filler end blocks fora staggered corner that give the appearance the logs are notched whenstacked. Siding pieces are notched and filler end blocks are inserted atthe joint to complete the log end. FIGS. 15-18 show cast tail clusters34 to be applied to an unfinished exterior corner of a structure sidedwith the simulated log siding of the subject invention. Each cluster isa plurality of molded log butt ends stacked to appear to be a staggeredlog corner. The cluster is aligned with the siding pieces to give theappearance of a series of continuous stacked logs. The clusters can beattached to the sided structure with a flange or straps.

The simulated log siding of the subject invention is an economical andrealistic solution to an increasing market for authentic log-likestructures. The siding can be mass produced and can be applied to newconstruction or be presented as an option during re-siding. The subjectsiding is easy to install and can be applied by a do-it-yourselfer. Thesiding provides an authentic log profile with wood aesthetics and offerstraditional log structure details.

It is understood that the foregoing examples are merely illustrative ofthe present invention. Certain modifications of the articles and/ormethods may be made and still achieve the objectives of the invention.Such modifications are contemplated as within the scope of the claimedinvention.

The invention claimed is:
 1. A molded horizontally elongated sidingmember for use on a structure to simulate log construction, the sidingmember comprising: a first edge and a second edge, the member comprisingan exterior convex surface and an interior concave surface between thefirst edge and the second edge; a first end and a second end defining alength of the member; the exterior convex surface cast in a reverse moldof a structural log to replicate the texture of a structural log; and atleast one flange along at least one of the edges to attach the member tothe structure; wherein the siding member is cast of engineeredcementitious composite and is an open trough and wherein the sidingmember contacts the structure at least along one of the first edge, thesecond edge, and the at least one flange.
 2. The siding member of claim1, wherein said length of said siding member is from about eight feet toabout twelve feet.
 3. The siding member of claim 1, wherein saidexterior convex surface is cast to replicate the texture of a peeledlog.
 4. The siding member of claim 1, wherein said exterior convexsurface is cast to replicate the texture of a partially peeled log. 5.The siding member of claim 1, wherein said exterior convex surface iscast to replicate the texture of a hand-hewn log.
 6. The siding memberof claim 1, further comprising a non-supporting foam core inserted intosaid reverse mold after said engineered cementitious composite is insaid mold.
 7. The siding member of claim 1, wherein said at least oneflange is embedded in said siding member.
 8. The siding member of claim7, wherein said flange is formed from a material selected from the groupconsisting of metal hardware cloth, metal lath and a synthetic knittedmaterial.
 9. The siding member of claim 1, wherein said at least oneflange is integral to and an extension of the siding member and isformed from the engineered cementitious composite material.
 10. Thesiding member of claim 1, wherein said at least one of said ends isformed to resemble a portion of the butt end of a structural log. 11.The siding member of claim 10, wherein said siding member furthercomprises a filler block resembling the remainder of the butt end of thestructural log.
 12. The siding member of claim 1, wherein when at leastone of said first end or said second end contacts at least one of afirst end or a second end of another like siding member at a butt joint,the texture to replicate a structural log on said exterior convexsurface of said siding member matches texture to replicate a structurallog on an exterior convex surface of the another like siding member sothe texture spans the joint.